Wall stud assembly for modular walls

ABSTRACT

A wall stud assembly includes first and second elongate stud members and a plurality of connectors. The first elongate stud member includes a back section, a front section substantially parallel to the back section, and two substantially parallel side portions connecting, and extending between, the back and front sections. The parallel side portions comprise engagement extensions extending beyond and forming a receiver portion with the front section. The back section extends beyond the side portions. The second elongate stud member comprises a back wall engaging the front section of the first elongate stud member and two side walls substantially parallel to and extending from the back wall configured to engage the engagement extensions of the first elongate stud member. The second elongate stud member also comprises two wall flanges substantially perpendicular to and extending from the side walls. The plurality of connectors attach the side walls to the engagement sections.

BACKGROUND OF THE INVENTION

This invention relates generally to a wall stud assembly and more particularly to a wall stud assembly for clean rooms and portable/in-plant buildings.

The buildings of the type which utilize wall stud assemblies are typically prefabricated and ready for assembly at the building site. Such buildings include in-plant offices, guard houses, food service buildings, control rooms, toll booths, parking lot booths, noise control buildings, clean rooms, and the like. Such buildings are formed from load-bearing wall structures as opposed to mere partitions. These portable buildings must be of quality construction, strong and durable. They should be energy efficient, have good sound control and low maintenance. Other characteristics of such buildings are that they must be relatively easy to assemble at the job site and easily disassembled for moving to a different location if desired. They should also be economical.

Such building structures are well-known in the art as are wall studs for use with such building structures. Typically, such wall studs are of steel or extruded aluminum and have side recesses for receiving the side edges of wall panels to form the walls of the building.

One such prior art wall stud has first and second stud members, each of which is generally U-shaped in cross-section with a base and opposing sides forming an open side and a base side of each stud member. Each stud member has laterally extending flanges extending outwardly from the side walls at the open side. The base sides of the stud members are affixed in surface engagement with the open sides of the stud members facing outwardly, therefore to sandwich a wall panel between the outwardly extending flanges of the stud members. The base sides are affixed to each other by means of anchoring screws which extend through the base sides of the stud members. Thus, the fasteners or screws are oriented along a single longitudinal line.

Such assemblies suffer certain drawbacks, however. For example, such assemblies are not as strong as desired. Thus, in order to withstand typical loads, the stud assemblies are generally limited to twelve feet in height. Moreover, such assemblies are adapted to walls of limited thickness, generally about 3 inches thick, while in certain situations thicker walls (such as 4 to 5 inches thick) are desired for temperature or sound insulation, ventilation passageways or other reasons. Although the width of the sides of the U-shaped stud members may be increased thereby to deepen the U-shaped cross-section to accommodate thicker walls, it has been found that retooling costs to effect such changes increases the cost of the stud assembly significantly. In addition, it does not adequately address the desire for stronger stud assemblies.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a wall stud assembly comprising a first elongate stud member, a second elongate stud member, and a plurality of connectors is provided. The first elongate stud member comprises a back section, a front section substantially parallel to the back section, and two substantially parallel side portions connecting and extending between the back section and the front section. The parallel side portions comprise engagement extensions extending past the front section forming a receiver portion with the front section. The back section extends beyond the side portions. The second elongate stud member comprises a back wall configured to engage the front section of the first elongate stud member and two side walls substantially parallel to and extending from the back wall and each configured to engage the engagement extensions of the first elongate stud member. The second elongate stud member also comprises two wall flanges substantially perpendicular to and extending from the side walls. The plurality of connectors attach the side walls of the second elongate stud member to the engagement sections of the first elongate stud member.

In another aspect, a wall stud assembly is provided that comprises a substantially rectangular first elongate stud member comprising engagement extensions extending therefrom and forming a receiver portion and a second elongate stud member substantially forming a channel and configured for insertion into the receiver portion.

In still another aspect, a wall assembly is provided which comprises a plurality of wall sections and a plurality of wall stud assemblies, each wall stud assembly is between a pair of wall sections. The wall stud assemblies each comprise a substantially rectangular first elongate stud member comprising engagement extensions extending therefrom and forming a receiver portion and a second elongate stud member substantially forming a channel and configured for insertion into the receiver portion of the first stud member. The first elongate stud member and the second elongate stud member are configured to engage the wall sections.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a wall stud assembly.

FIG. 2 is a front view of the wall stud assembly shown in FIG. 1.

FIG. 3 is a front view of a portion of a wall assembly including wall stud assemblies shown in FIG. 1 positioned between wall sections.

FIG. 4 is a perspective view of a portion of a wall fabricated using the wall stud assembly shown in FIG. 1.

FIG. 5 is a top view of another wall stud assembly.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a top view of a wall stud assembly 10 including a first elongate stud member 12, a second elongate stud member 14, a cover section 16 and a plurality of connectors 18. First elongate stud member 12 includes a back section 20, a front section 22 substantially parallel to back section 20, and two substantially parallel side portions 24 and 26 connecting and extending between back section 20 and front section 22. As such, first elongate stud member 12 is substantially rectangular in cross-section. Parallel side portions 24 and 26 also include engagement extensions 28 and 30 respectively, that extend beyond front section 22, and therefore extend from the substantially rectangular cross-section. In one embodiment, engagement extensions 28 and 30 and front section 22 form a receiver portion 32. Back section 20 extends beyond parallel side portions 24 and 26 and engages a modular wall section (shown in FIG. 3) to form a portion of a wall.

In one embodiment, junctions 34 and 36 are formed where back section 20 and parallel side portions 24 and 26 meet. Junctions 34 and 36, in one embodiment, each include an arcuate section 37 extending from back section 20 to the respective parallel side portion in order to provide strength to junctions 34 and 36.

Second elongate stud member 14 includes a back wall 40 configured to engage front section 22 of first elongate stud member 12 in a surface-to-surface manner. Second elongate stud member 14 also includes two side walls 42 and 44 substantially parallel to and extending from back wall 40 and two wall flanges 46 substantially perpendicular to and extending from side walls 42 and 44 respectively. Back wall 40 and side walls 42 and 44 form a channel, sometimes referred to as a raceway, for insertion of wiring and the like as further described below. Back wall 40 and portions of side walls 42 and 44 (e.g., the channel) are inserted into receiver portion 32 of first elongate stud member 12 as described in more detail below.

In one embodiment, side walls 42 and 44 are each configured to engage engagement extensions 28 and 30 respectively such that connectors 18 are utilized to attach side walls 42 and 44 to engagement sections 28 and 30. In a specific embodiment, side walls 42 and 44 each include a V-shaped portion formed therein having a first side 47 and a second side 48. In the illustrated embodiment, engagement extensions 28 and 30 are at least partially configured to engage first sides 47 of the V-shaped portion. Engagement sections 28 and 30 include a first segment 50 extending inward from parallel side portions 24 and 26, a second segment 52 extending from first segment 50 that is substantially parallel to parallel side portions 24 and 26, and a third segment 54 extending outward from second segment 52, segments 50, 52, and 54 effectively forming a channel. As illustrated in FIG. 1, surfaces of second segments 50 are adjacent to a portion of side walls 42 and 44 and third segments 54 are adjacent to first sides 47 of the V-shaped portion of side walls 42 and 44 for insertion of connectors 18.

In one embodiment, connectors 18 are self tapping screws. Alternatively, any means for connecting adjacent surfaces can be used, including rivets, nuts and bolts, pins, rods, and nails.

Cover 16, which in one embodiment is configured to engage side walls 42 and 44 of second stud member 14, forms a portion of a wall. Cover 16 includes a plurality of clips 60 extending substantially perpendicularly therefrom and configured to provide a snap fit connection with side walls 42 and 44. Particularly, clips 60 include a protrusion 62 which snaps into the V-shaped portion of side walls 42 and 44 engaging a surface of second side 48 of the V-shaped portion. When cover 16 is fitted onto second elongate stud member 14 as previously described, a channel is formed for routing one or more of ducting, piping, wiring, pressure lines, cabling, plumbing, and the like.

Ends 70 of cover 16 extend a short distance beyond the location of clips 60. In a particular embodiment, as shown in FIG. 1, wall flanges 46 are formed with a notch 72 such that ends 70 of cover 16 fit within. Further, a surface 74 of cover 16 is substantially planar with surfaces 76 of wall flanges 46.

FIG. 2 is a front view of a portion of wall stud assembly 10 shown in FIG. 1 with cover 16 removed. Surfaces 76 of wall flanges 46 extend outward from notches 72 that are formed in wall flanges 46. Back wall 40 of second elongate stud member 14 is shown as are portions of connectors 18 that have been inserted into and through first sides 47 (not shown) of the V-shaped portion of side walls 42 and 44 of second elongate stud member 14 and third segments 54 (not shown) of engagement sections 28 and 30 (not shown).

FIG. 3 is a front view of a portion of wall assembly 100 which includes wall stud assemblies 10 positioned between wall sections 102 with covers 16 in place. Providing more detail, FIG. 4 is a perspective view of a portion of wall assembly 100 fabricated using wall stud assembly 10 shown in FIG. 1 and wall sections 102. It should be noted that dimensions of wall stud assembly 10 can be adjusted according to a particular application. More specifically, a depth of second elongate stud member 14 from wall flanges 46 to back wall 40 (and therefore dimensions of first elongate stud member 12) is adjustable. Adjusting the depth allows insertion of, for example, conduit 104 and junction box 106 for routing of electricity. Other embodiments (i.e., ducting, electrical junction boxes, piping, wiring, pressure lines, cabling, and plumbing) are also contemplated all of which are accessible by removing cover 16 from wall stud assembly 10.

The configuration of the components of wall stud assembly 10 also allows for construction of wall section from a single side of wall assembly. By placing a first elongate stud member 12 in position between two respective wall sections 102, a second elongate stud member 14 is then insertable into the receiver portion of first elongate stud member 12 and connectors 18 are inserted as described above, followed by the snapping in place of cover 16 (after any insertion of wiring and the like).

FIG. 5 is a top view of a wall stud assembly 200, which is similar to wall stud assembly 10 (shown in FIG. 1) which illustrates changed dimensions according to a particular application as described above. Components of wall stud assembly 200 which are substantially similar to components of wall stud assembly 10 are denoted utilizing the same reference numerals. More specifically, and in comparison to wall stud assembly 10, a depth of second elongate stud member 14 from wall flanges 46 to back wall 40 has been increased, forming a deeper channel portion for insertion of electrical junction boxes and the like as described above. Likewise, a depth of first elongate stud member 12, specifically a length of substantially parallel side portions 24 and 26 are reduced. In addition, wall stud assembly 200 includes an alternative arrangement for engagement extensions 202 and 204. Rather than being comprised of a first segment 50, a second segment 52, and a third segment 54 as is the case with wall stud assembly 10, engagement extensions 202 and 204 include first members 206 that are substantially parallel to parallel side portions 24 and 26, and extend from junctions 208 (similar to junctions 34 and 36 (shown in FIG. 1)) where parallel side portions 24 and 26 and front section 22 meet. First members 206 are further adjacent to portions of side walls 42 and 44 of second elongate member 14. A second member 210 extends outward from first member 206 and is equivalent to third segment 54 (shown in FIG. 1).

The above described embodiments allow for the construction of temporary walls that provide routing for electricity, fluids and the like, while also providing a relatively smooth wall surface of the kind typically utilized in clean room construction. Therefore, the wall stud assembly described herein allows for the simple construction of any size room having walls with properties desirable for use in clean rooms and also providing a sturdy construction.

The wall stud assembly described herein also allows for construction of in-plant and portable buildings which must support a load such as a roof, as opposed to a partition system that provides little or no structural vertical support. Moreover, wall stud assemblies 10 and 200 are configured not to bow under vertical or lateral loads.

While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. 

1. A wall stud assembly comprising: a first elongate stud member comprising: a back section; a front section substantially parallel to said back section; two substantially parallel side portions connecting, and extending between, said back section and said front section and comprising engagement extensions extending beyond said front section, said engagement extensions and said front section forming a receiver portion, said back section extending beyond said side portions; a second elongate stud member comprising: a back wall configured to engage said front section; two side walls substantially parallel to and extending from said back wall, each said side wall configured to engage said engagement extensions; two wall flanges substantially perpendicular to and extending from said side walls; and a plurality of connectors attaching said side walls to said engagement sections.
 2. A wall stud assembly according to claim 1 wherein said wall flanges are configured to form a portion of a wall.
 3. A wall stud assembly according to claim 1 wherein said back section is configured to form a portion of a wall.
 4. A wall stud assembly according to claim 1 wherein said side walls comprise a V-shaped portion therein and said engagement extensions at least partially configured to engage a portion of said V-shaped portion.
 5. A wall stud assembly according to claim 4 wherein said connectors are configured to attach said V-shaped portion to said engagement extension.
 6. A wall stud assembly according to claim 1 wherein said engagement extensions comprise: a first segment extending inward from said parallel side portion; a second segment extending from said first segment that is substantially parallel to said parallel side portion; and a third segment extending outward from said second segment and shaped to butt one side of said V-shaped portion for insertion of said connectors.
 7. A wall stud assembly according to claim 1 wherein said connectors comprise self tapping screws.
 8. A wall stud assembly according to claim 1 further comprising a cover section configured to engage said side walls and form a portion of a wall.
 9. A wall stud assembly according to claim 8 wherein said cover section comprises a plurality of clips providing a snap fit connection with said side walls.
 10. A wall stud assembly according to claim 8 wherein said cover section and said second stud member form a channel for routing one or more of ducting, electrical junction boxes, piping, wiring, pressure lines, cabling, and plumbing.
 11. A wall stud assembly according to claim 8 wherein said wall flanges each comprise a surface and a notch formed therein such that said cover when engaged is substantially planar with said surfaces of said wall flanges.
 12. A wall stud assembly according to claim 1 wherein said engagement extensions comprise: a first member substantially parallel to said parallel side portion and extending from junctions of said parallel side portion and front section; and a second member extending outward from said first member and shaped to be adjacent one side of said V-shaped portion for insertion of said connectors.
 13. A wall stud assembly comprising: a substantially rectangular first elongate stud member comprising engagement extensions extending therefrom and forming a receiver portion; and a second elongate stud member substantially forming a channel and configured for insertion into said receiver portion.
 14. A wall stud assembly according to claim 13 wherein said second elongate stud member comprises wall flanges extending therefrom and configured to be substantially flush with respective wall sections.
 15. A wall stud assembly according to claim 14 comprising a cover section, said cover section configured to engage said second elongate stud member such that when engaged, said cover section is substantially flush with said wall flanges.
 16. A wall stud assembly according to claim 13 comprising a plurality of connectors attaching said second elongate stud member to said first elongate stud member.
 17. A wall stud assembly according to claim 13 wherein the channel formed by said second elongate stud member is sized for insertion of one or more of ducting, electrical junction boxes, piping, wiring, pressure lines, cabling, and plumbing.
 18. A wall stud assembly according to claim 13 wherein said first elongate stud member comprises a back section opposite the receiver portion, said back section extending past the substantial rectangle and configured to engage and be substantially flush with respective wall sections.
 19. A wall stud assembly according to claim 13 wherein a change in a depth of the channel formed by said second elongate stud member result in a corresponding change in a depth of the rectangular cross-section of said first elongate stud member.
 20. A wall stud assembly according to claim 13 wherein the channel formed by said second elongate stud member comprises two sides, said sides formed with an irregularity for the insertion of connectors therethrough and into said engagement extensions.
 21. A wall assembly comprising: a plurality of wall sections; and a plurality of wall stud assemblies, each said wall stud assembly extending between a pair of said wall sections, said wall stud assembly comprising a substantially rectangular first elongate stud member comprising engagement extensions extending therefrom and forming a receiver portion and a second elongate stud member substantially forming a channel and configured for insertion into said receiver portion, said first elongate stud member and said second elongate stud member configured to engage said wall sections.
 22. A wall assembly according to claim 21 wherein the channel formed by said second elongate stud member is sized for insertion of one or more of ducting, electrical junction boxes, piping, wiring, pressure lines, cabling, and plumbing.
 23. A wall stud assembly comprising: a first elongate stud member comprising a back section, a front section, two side portions connecting said back section and said front section, and engagement extensions extending beyond said front section, said engagement extensions and said front section forming a receiver portion; a second elongate stud member comprising a back wall configured to engage said front section, two side walls extending from said back wall, each said side wall configured to engage said engagement extensions, and two wall flanges extending from said side walls; and an elongate cover configured to fit between said wall flanges. 